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I haven't had a problem loading my 1990's vintage 77/44 to magazine length, so your freebore may be on shorter end of tolerances......but....
My Nosler #4 says SAMMI range for OAL is 1.660" to 1.723", which means your "shorter" loads are still long.
Nosler #4 also discusses problems seating their longer BT's deep enough to work in the 77/44 magazine, but says SAMMI length can be exceeded in rifles where the magazine allows as long as bullet does not contact the rifling.
Contact hard enough to pull bullets is probably creating pressures issues.
Tom
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